medemagroup Mini Crosser X-Joy User manual

Service Manual Mini Crosser X-Joy
1533-2007-S ver. 1.0.3 - February 2020 GB
medemagroup

Service manual 1533-2007-S 2 of 84 Version 1.0.3 - 2020
Medema Production A/S
This vehicle was supplied by: Date: /
Serial number: ___-______________-______-_______
Delivery date: ________________ Year 20______
Medema A/S
Enggårdvej 7
Snejbjerg
DK-7400 Herning
Denmark
Telefon: [phone]
Mail: [email protected]
Dealer:
For this product You can expect to nd the following documentation:
• User manual
• Service manual
• Spare parts list
• Presell information.

Service manual 1533-2007-S 3 of 84 Version 1.0.3 - 2020
Medema Production A/S
Content
Content................................................................................... 3
Introduction............................................................................ 5
Intended occupant................................................................. 6
Help for the visually impaired .............................................. 6
FSN (Field Safety Notice)...................................................... 6
Symbols.................................................................................. 7
Warning! ................................................................................. 7
Joystick .................................................................................. 7
Contagion!.............................................................................. 7
Storage ................................................................................... 8
Cleaning ................................................................................. 8
Safe servicing ........................................................................ 9
Tool list ................................................................................... 10
Declaration of conformity..................................................... 11
Safety check Joystick ........................................................... 12
General care and maintenance ............................................ 13
Insurance................................................................................ 14
Designations.......................................................................... 15
Designations Joystick........................................................... 16
Designations functions......................................................... 17
Joystick lock / unlock ........................................................... 18
Preparations / Adjustments prior to use ............................. 19
Seat rotation........................................................................... 21
Serial number......................................................................... 22
Driving the Mini Crosser X-Joy ........................................... 23
Specic driving situations.................................................... 28
Anti-tilt wheels / stabilisers .................................................. 30
Programming ......................................................................... 31
Service summary for Mini Crosser X-Joy model................ 32
Troubleshooting .................................................................... 36
Programming ......................................................................... 37
LED ........................................................................................ 38
Batteries ................................................................................. 39
Battery disposal..................................................................... 39
Charging................................................................................. 40
Fuses ...................................................................................... 42
Brakes..................................................................................... 43
Disengagement...................................................................... 44
Transporting by motor vehicle ............................................. 45
Securing to vehicle oor with belts..................................... 46
Transporting by plane ........................................................... 49
Towing .................................................................................... 49

Service manual 1533-2007-S 4 of 84 Version 1.0.3 - 2020
Medema Production A/S
Changing the wheels............................................................. 50
Replace headlights................................................................ 52
Replace the front springs ..................................................... 54
Replace rear spring............................................................... 55
Replace tail light.................................................................... 56
Replace batteries................................................................... 57
Replace transaxle.................................................................. 58
Replace the magnetic brake................................................. 61
Replace fuses ........................................................................ 63
Replace coal........................................................................... 64
Introduction to the Ergo2 seat ............................................. 66
Basket on seatback............................................................... 71
Introduction to the Eblo seat................................................ 72
Flame resistance ................................................................... 73
Front wheel alignment, 4W................................................... 74
Dimensioned drawing, Mini Crosser X-Joy ........................ 75
Technical data........................................................................ 76
Own notes .............................................................................. 82

Service manual 1533-2007-S 5 of 84 Version 1.0.3 - 2020
Medema Production A/S
Introduction
This manual contains servicing instructions for the Mini Crosser
X-Joy Model mobility scooter.
The Service Manual is a supplement to our Spare Parts Cata-
logue and User Manual.
You are now the owner of an electric mobility wheelchair devel-
oped for use indoors as well as outdoors. It is what is called a
Class C vehicle according to the European standard EN 12184.
The Mini Crosser X-Joy is designed for safe travel for at least
10 years, up to a max. of 5,000 hours, provided it is serviced
and safety-checked every third year, corresponding to 1500
hours of operation. The service must be carried out either by
Medema A/S or an authorised workshop.
IMPORTANT! For safety reasons it is of the utmost importance
that the servicing and safety check intervals are complied with,
as this minimises the risk of brake failure and short-circuits in
the wiring, which could generate heat and cause a re.
If help is required with troubleshooting, Medema A/S is always
happy to provide telephone assistance. If the problem seems
to be an electrical fault that prevents the scooter from working,
please tell us the error code. This can be found on the battery
indicator on the control panel. Read more about this in the sec-
tion on Troubleshooting.
Please also have the scooter’s serial number handy when con-
tacting Medema A/S.
If you have any questions that are not answered directly by this
manual, you are always welcome to contact us at:
Medema A/S
Tel: [phone]
Email: [email protected]
Internet: www.medema.com
NB: Errors and omissions excepted. Specications subject to change.
Medema Production A/S also reserves the right to update the service
manual in line with any modications or improvements to the product.

Service manual 1533-2007-S 6 of 84 Version 1.0.3 - 2020
Medema Production A/S
Intended occupant
The intended occupant of the wheelchair is a person with lim-
ited ability of walking themselves.
The wheelchair is equipped with a joystick control which makes
it usable for an occupant who only has low functionality in the
ngers. It can be driven with only one hand either left or right.
The occupant must be able to see in order to register trafc sig-
nals and other road users when driving in trafc. The occupant
can be deaf and/or speechless.
The occupant must have a cognitive ability to understand the
operation of the joystick and its buttons and icons.
The maximum occupant weight is 150 kg.
Help for the visually impaired
If you have difculty reading small print in the user manual, we
recommend that you visit our website, where you can read this
manual in PDF format. You can enlarge the PDF manual on
your PC monitor to suit your needs and preferences.
If you nd it difcult to understand the manual and have general
questions about the product, please feel free to contact us. You
can nd our contact info on page two in this user manual.
You can nd manuals for all our products on our web page
www.medema.dk. Or contact Medema A/S, and we can send
the manuals in a mail for you. Find the contact information on
page two in this manual.
FSN (Field Safety Notice)
All information concerning safety can be found at www.mede-
ma.com, which is always updated with the latest safety informa-
tion. In the event of important safety-related changes, we will
notify our customers directly (FSN).

Service manual 1533-2007-S 7 of 84 Version 1.0.3 - 2020
Medema Production A/S
Symbols
Used in the manual to indicate sections describing situations
where extra care is required owing to the risk of personal injury.
Used to indicate sections on electromagnetic compatibility (EMC).
Warning!
For safety reasons the vehicle must not be lent to persons who
are not completely familiar with it. The vehicle is designed for
one person only.
The Mini Crosser X-Joy has been designed for users weighing
max. 150 kg.
Joystick
The joystick control box must not be exposed to extremes
of temperature or kept in a damp environment for extended
periods.
The joystick control box must not be subjected to heavy knocks.
Do not switch off the control box while driving, except in an
emergency, as this may damage the electronics.
For cleaning, use a damp cloth with slightly soapy water.
Do NOT allow any water or moisture to enter the control box.
Contagion!
A standard Mini Crosser is equipped with tyres that does not
contage, but if another type of tyres are used, it can sometimes
rub off on oor coverings, particularly linoleum. Medema A/S as-
sumes no responsibility in case of contagion.
To prevent this, we recommend that you protect delicate oors
with some sort of driving surface.

Service manual 1533-2007-S 8 of 84 Version 1.0.3 - 2020
Medema Production A/S
Storage
The Mini Crosser is a CLASS C product, designed for use in all
types of weather. The scooter should, however, be stored and
charged under cover at temperatures in excess of 0°C. The
charger must also be kept dry.
If the scooter is not going to be used for a long time, it is advis-
able to protect the tyres by chocking the scooter up. It is also a
good idea to cover the scooter to protect it from dirt, dust and
sunlight.
Cleaning
The Mini Crosser should be cleaned with a damp cloth. A little
washing-up liquid can be used if necessary. The plastic covers
can be polished with an ordinary glass cleaner or car wax.
Note!
Using a high-pressure cleaner or hose may damage the Mini
Crosser’s electronics.

Service manual 1533-2007-S 9 of 84 Version 1.0.3 - 2020
Medema Production A/S
Safe servicing
• To avoid injuries to both the service engineer and the subsequent
user of the scooter, it is important to get to know the product be-
fore servicing it.
• Be particularly aware of the following:
• The Mini Crosser MUST be turned off at the main switch. If electri-
cal components are being serviced, the positive terminal on the
battery MUST also be disconnected.
• If the voltage needs to be measured in the course of troubleshoot-
ing, take great care not to short-circuit anything.
• Take great care not to short-circuit the battery terminals.
• Be careful not to lift heavy parts such as the seat, battery and mo-
tor gear incorrectly or drop them.
• Make sure to raise one rear wheel off the ground so that the
scooter cannot drive off accidentally.
• Use professionally maintained tools.
• Where lock nuts are used, NEW ones MUST be tted when the
scooter is reassembled.
• Take care to t new cable strips in the same way as the old ones.
Make sure that no cables can be trapped by moving parts or stick
out in such a way as to catch on things.
• End every service by making sure that the product is roadworthy:
- Check that all the connectors are plugged in correctly.
- Check that all the mechanical parts are properly secured.
• Turn the scooter on and check
- That the magnetic brake clicks when the accelerator is activated.
- When the accelerator is released, it must not be possible to
push the scooter.

Service manual 1533-2007-S 10 of 84 Version 1.0.3 - 2020
Medema Production A/S
Tool list
The following tools are needed to service the scooter:
• Circlip pliers
• Allen keys
• Box spanners, 7-17 mm
• Open-ended spanners, 7-17 mm
• Phillips and torx screwdrivers, 10/15/20/25 slot
• Needle-nose pliers
• Side-cutting pliers
• Plastic hammer
• Set of punches
• Retractable knife
• Steel brush
• Water pump pliers
• Wire strippers
• Crimping tool
• Pliers for Molex 5556/5558 crimps
• Riveting pliers
• Small cable ties
• Multimeter
• Battery tester
• Tyre pressure gauge
• Tyre pump with Schrader valve
• Acid-free oil and grease
• Loctite El-zink = 2400, A2 = 2700, Bearings = 6300
• Cable ties
• PC
• PC Programming package

Service manual 1533-2007-S 11 of 84 Version 1.0.3 - 2020
Medema Production A/S
Declaration of conformity
Medema Production A/S hereby declares that:
Machine: Electric mobility wheelchair
Use: Transport of walking-disabled people
Model No: Mini Crosser X-Joy
Complies with the Medical Device Directive 93/42/EEC
The product is accredited according to standard DS/EN 12184
- Electrically powered wheelchairs, scooters and their chargers -
Requirements and test methods.
The product is risk analysed in accordance with the harmonized
standard DS/EN ISO 14971:2012 Medical devices - Application
of risk management to medical devices.
The Mini Crosser can, for a fee, be taken to the nearest dealer
for disposal in accordance with current environmental regula-
tions.
Manufacturer: Medema A/S
Address: Enggårdvej 7, DK-7400 Herning
Tel. [phone]
Date: 31.01.2018 Signature: _____________________
Managing director Finn Dose

Service manual 1533-2007-S 12 of 84 Version 1.0.3 - 2020
Medema Production A/S
Safety check Joystick
Daily safety check:
The electronic system has an integrated safety check which
runs up to 100 times per minute. To supplement this check, you
should carry out the following regular checks.
• Switch off the electronic system
• Check if the joystick is bent
• Check if the joystick is damaged in any other way
• Check that it returns to the central position when you release it
If the check reveals any problems, contact a competent service
engineer before using the wheelchair again.
Weekly safety check:
Parking brake: This test must be carried out on a at surface
with at least one metre of free space around the wheelchair.
• Start the wheelchair and slowly move the joystick forward. There
is a clicking sound. (The wheelchair may start to move in this set-
ting).
• Immediately release the joystick and listen for the clicking sound,
which should occur within one second.
Repeat in all directions.
• Check that the rubber bellows around the joystick is intact. This is
important, as the bellows prevent moisture getting into the elec-
tronic system.
• Check that the control box is properly secured.
If the check reveals any problems, contact a competent service
engineer before using the wheelchair again.
Monthly check
Check the tyre pressure at least once a month. See technical
data for pressure.

Service manual 1533-2007-S 13 of 84 Version 1.0.3 - 2020
Medema Production A/S
General care and maintenance
A Mini Crosser X-Joy does not require much maintenance. It
should be kept in a generally good condition, however. The fol-
lowing should be checked regularly:
• Tyre pressure (if pneumatic tyres are tted)
• Tyre wear
• Keep the control panel, the charging socket and the electronics
box under the seat dry.
• Battery charging
Never wash the Mini Crosser with a high-pressure cleaner or di-
rect water jet! This could damage the Mini Crosser’s electronics.
To keep the Mini Crosser in good condition safety-wise, we rec-
ommend the following regular checks:
Daily: (user)
Test the indicators and driving lights before using the Mini
Crosser in the dark or poor visibility.
Every three months:
Test the brakes and motor disengagement
With the disengagement lever up, it must not be possible to
push the Mini Crosser.
Test the brake disengagement function
When the brake disengagement lever is down, the battery indi-
cator should ash to show an error if the Mini Crosser is turned
on. In this case the Mini Crosser must not be able to move
when the accelerator is activated.
Test the hand brake.
Apply the hand brake for a couple of seconds at low speed.
This will ensure that the lever arm and brake shoes do not seize
up.
Lubricate the lever arm on the brake hub with acid-free oil - left-
hand rear wheel.

Service manual 1533-2007-S 14 of 84 Version 1.0.3 - 2020
Medema Production A/S
Service intervals
The Mini Crosser X-Joy is designed to require a minimum of
maintenance.
However, you are recommended to take it to your dealer for
inspection every third year.
IMPORTANT! For safety reasons it is of the utmost importance
that the servicing and safety check intervals are complied with,
as this minimises the risk of brake failure and short-circuits in
the wiring, which could generate heat and cause a re.
Insurance
In the eyes of the law a Mini Crosser X-Joy with a maximum
speed of 13 km/h is a cycle, so separate insurance is not re-
quired.
Most contents/home insurance policies include third-party liabil-
ity insurance for cyclists and so also cover Mini Crosser X-Joy
users.
We recommend that you talk to your insurance company about
this when the vehicle is delivered. If necessary, comprehensive
insurance will have to be taken out separately.

Service manual 1533-2007-S 15 of 84 Version 1.0.3 - 2020
Medema Production A/S
Designations
The following designations refers to the explanation later in the
instruction book.
Joystick
Control panelHeadrest
Thermal fuse
Manual
Disengagement lever
Seat rotation
Release handle
forw. / backw.
Eye for restraints
Directional
signals
Charging
socket
Serial number on
vehicle.
Eye for
restraints
Hand brake
Handbrake
Electrical
Disengagement
Directional
signals
Stop light
Basket
Support handle

Service manual 1533-2007-S 16 of 84 Version 1.0.3 - 2020
Medema Production A/S
Designations Joystick
P&G R-net
1 Start/stop-button
2 Battery indicator
3Driving prole
4 Warning blinkers
5 Mode LED
6 Light
7 Mode button (electric functions)
8 Blinkers left/right
9 Mode LED
10 Joystick
11 Speed increase / decrease
12 Horn
1
5
6
12
7
8
2
4
3
9
11
10

Service manual 1533-2007-S 17 of 84 Version 1.0.3 - 2020
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Designations functions
P&G R-net
1 Press the button 1 to start the Mini Crosser. Wait untill the battery indicator
is stabil (3-5 sec).
2 Battery indicator
Show a more precis indication after approximately one minute of driving.
When all the LED is lit, the batteries are fully loaded. When only a couble of
yellow lights are visual - charge as soon as possible. If only the red LED are
showing, or if they are blinking - charge right away.
3Driving prole show what the maximum speed are set to. There are ve
LED. One LED refer to lowest speed and ve LED refer to maximum speed.
4 Warning blinkers - all blinkers are activated. Even if the vehicle is turned of,
it will not stop blinking. To turn of the warning blinkers, the vehicle must be
turned on, and press the button for warning blinkers button (4) again.
5Mode LED - lights up when the associated function is active
6 Light - turn the front- and backlight on. Turn it off again by pressing the light
button (6) again.
7 Mode button - (electric functions). Scrolls through the available electric
functions. Use joystick up/down to adjust.
8Blinkers (right and left) start blinkers on the side the arrow shows.
9Mode LED - lights up when the associated function is active
10 Joystick - controls the direction and speed of the vehicle.
11 Speed increase/decrease - increase or decrease the maximum speed.
12 Horn - powerful electric horn.
1
5
6
12
7
8
2
4
3
9
11
10

Service manual 1533-2007-S 18 of 84 Version 1.0.3 - 2020
Medema Production A/S
Joystick lock / unlock
X-Joy can be locked, so unauthorized persons cant use it.
• Turn on the Joystick
• Push and hold the on/off button. After 1 sec, you will hear a short
audio signal.
• Let go of the on/off button. Move the joystick forward until you
hear a short audio signal.
• Move the joystick backward until you hear a long audio signal.
• X-Joy is locked.
It is now impossible to drive the X-Joy.
Unlock:
• Turn on the Joystick
• Move the joystick forward until you hear a short audio signal.
• Move the joystick backward until you hear a short audio signal.
• Let go of the joystick and you will hear a long audio signal.
• X-Joy is now unlocked.

Service manual 1533-2007-S 19 of 84 Version 1.0.3 - 2020
Medema Production A/S
Preparations / Adjustments prior to use
Adjusting the height of the seat
Lift both armrests up, and fold the seatback. Release the handle
so the seat can turn. Turn a little and lift the seat off.
Make sure you keep your back straight when lifting the seat,
which is very heavy.
Lift the seat off the seat tube.

Service manual 1533-2007-S 20 of 84 Version 1.0.3 - 2020
Medema Production A/S
Hight adjustment seat post standard
The release button pressed in. Press the
button out to release the seat tube.
Release button pressed out. Now the
seat tube can be moved up/down to
the height you wish. Press the release
button again and make sure it is tted in
one of the 5 holes in the seat tube.
Loosen the counter nut.
Use spanner, 17 mm.
Adjust the seat post to the desired
position. The seat post is marked with a
ring at each centimetre.
Be aware that the black line is holding its position after movement, so the seat is
straight in front of the steering.
Tighten the screw, here after the counter nut.
Mount the seat. Adjust the lining if necessary.
Hight adjustment seat post with position bolt (option)